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Mass Finishing Technical Information MASS FINISHING TECHNICAL INFORMATION MASS FINISHING Mass finishing is a process that automates the mechanical and chemical finishing of non-fixtured complex shaped parts. Mass finishing utilizes many types of energy generating equipment, abrasive medias and compounds that transmits the energy from the equipment thru the media to the parts being processed. The machinery energies the media to move in a random or precise flow around, into, and thru the parts being finished. The process can be wet or dry and will run a multitude of parts and processes at a time. Mass finishing can obtain repeatable results with a low cost per part. Process capabilities of Mass Finishing Mechanical Visual Deburring and edge radiousing Uniform finishing Surface refinement Blending Surface roughing Brighting Pre paint adhesion Cleaning Peening Satin Finishing Stress relieving Matte finishing Removal of tooling marks Pre plate and anodize finishing Factors that affect the mass finishing are: 1. Equipment 2. Media 3. Compounds 1. MASS FINISHING EQUIPMENT MASS FINISHING TECHNICAL INFORMATION There are a number of choices when selecting equipment for mass finishing. There can be a lot of overlap where various machines will accomplish the same finishing process results. Other factors to look at when choosing the right equipment will be: labor available to assist equipment processes, time available for finishing process within the cell or production cycle, capital, the part being processed, and other processes that can be incorporated (part unloading, washing, rinsing, drying, inhibiting,etc) into the equipment to reduce labor. Equipment available in the mass finishing industries. A. Vibratory machines B. High energy systems C. Specialty mass finishing systems A. VIBRATORY EQUIPMENT The energy that vibratory systems generate is derived from a 1200 to 3500 rpm electric motor rotating a eccentric weighted shaft. The shaft is attached horizontal to a tub vibratory machine or vertically to a bowl vibratory machine. The weighted rotating shaft generates a vibrating action that is transferred to the machine. The vibratory machines action vibrates the abrasive media (which is contained within the urethane lined u shaped channel of the machine) impacting the parts being processed within the media. Energy level low to moderate Media action Vibrating punching rolling action measured in millimeters of amplitude ranging from 1 to 8 mm, with 3-6 mm the normal operating range. Applications general deburring and finishing of machined parts, stampings, castings weldments and composite surface prep. MASS FINISHING TECHNICAL INFORMATION Tub Vibratory equipment Tub vibratory systems are comprised of a rectangular u shaped tub. The tubs can have various channel diameters and channel lengths. The tub is mounted and suspended on springs attached to the base of the machine. The motor and rotating shaft is located within the base. The shaft is attached to the bottom of the tub and run by a v-belt drive from the motor attached to the base. Advantages Disadvantages Long part processing Manual part unloading Easily divided, for running Small flat parts stick to the large parts that cant touch tub side walls. or different medias at one time Parts migrate to the drive end Smaller systems inexpensive of the tub decreasing media to and portable part ratio. Large systems can be built for continuous automation Bowl Vibratory Equipment Bowl vibratory machines are comprised of a donut shaped u channel tub. The bowl can have various channel sizes and overall diameters. The bowl is held suspended by springs that are attached to a round base. The eccentric shaft is mounted vertically thru the center column of the bowl. The motor can be in the base running the shaft by a v-belt drive or in some machines the motor is built around the shaft mounted within the center column. Advantages ! Disadvantages Internal part unloading and Restrictive on very long parts media separation Less part to part damage Mid level and up on capital investment Secondary operations such as media classification, part rinse, cleaning and drying Can be built for batch or continuous automation MASS FINISHING TECHNICAL INFORMATION B. HIGH ENERGY MACHINES Centrifugal high energy is a controlled centrifugal rotation of a disc or barrel creating an acceleration and de acceleration and a compressive flowing media action. The centrifugal finishing processes 7-20 times the energy of vibratory machines. The centrifugal high energy is not only is faster, but it also produces superior finishes than the media punching action of the vibratory machines. Energy levels high to very high- up to 20 times the energy of vibratory machines Media action Controlled centrifugal flowing compressive action Applications Super finishing, Deburr of small parts, good for flat part separation while processing, Drives small media into small areas with energy. Centrifugal Disc Machines The centrifugal disc(CD) utilizes the energy of a 100 to 200 rpm rotating disc at the bottom of a bowl container. The rotating disc accelerates the media to a stationary side wall which de accelerates it and then gets re accelerated back and down to the center of the disc. The continued media acceleration and de acceleration flow produces energy 7-15 times that of a vibratory machine. The CD machine is one of the few hight energy processes that can be automated. Advantages Disadvantages High energy Higher capital investment Easily automated Ring and rotor wear life costs approximately $1.00 per operating Flow thru water system for reline costs Quick time cycles for cellular manufacturing Large and heavy parts process numbers low because of part on part damage. Run wet or dry MASS FINISHING TECHNICAL INFORMATION Centrifugal Barrel Machines The centrifugal barrel (CB) equipment looks and operates like a ferris wheel with a cover. The energy is produced by a 100 to 240 rpm rotating turret with (generally 2-4 hexagon or octagon barrels) built within the turret that counter rotates at various rpm"s . The action of these fully enclosed high speed rotating barrels produce a compressive sliding grinding action. The CB produces the highest mechanical mass finishing process at up to 20 times the energy of vibratory finishing. Advantages Disadvantages High energy Very time consuming to load and unload barrels. Can run dividers in barrels to keep parts from damaging Cannot be automated Very short time cycles Batch processing only Run wet or dry Part radiusing up to .030 C. SPECIALTY HIGH ENERGY EQUIPMENT Magnetic Finishing equipment The energy from magnetic equipment is derived from rapid rotating magnets built under the tub container holding the parts and media. The changing polarity of the magnets run at very high speeds drive the magnetic stainless media within the tub to a very aggressive spinning action. Energy level Very high Media action High speed spinning of stainless pin and various shaped medias Applications Removes burrs from tiny holes, slots, knurled parts, and hard to get thread burrs. Works on non ferrous parts. Highly magnetic steel parts do not work because they move with the magnets. MASS FINISHING TECHNICAL INFORMATION Chemical Finishing The chemical finishing process(CF) produces a high rate of material removal and super surface refinement (down to 2 RA) by oxidizing the surface of Ferrous ( iron based ) materials, some non ferrous processes also work. The chemical ( occolic acid, citric acid, or phosphates) continuously activates the process parts surface allowing a very heavy ceramic media (120 to 140 lbs per cu ft) to remove the material at much higher rates. The usually non abrasive media acts as the chemical carrier as well as the surface scrubbing agent. The process produces a refined, bright finish with minimum edge radiusing. The CF process is generally used with bowl vibratory equipment but can be run in tubs vibrators, centrifugal disc and drag machines. All systems must use a very accurate compound delivery system. The low PH process chemical must be adjusted to normal discharge rates before flowing to sewer.The burnishing or brightening secondary compound(higher PH) step can be flowed into the same sediment tank as the process compound(lower PH) neutralizing for proper disposal. Energy level Very high material removal Media action Vibratory or flowing action basically carrying the compound and scrubbing the oxidized surface allowing for continuous re-oxidizing. Application Refining gears, finishing hand tools, gun parts that require very little radiusing. Surface refinement and brighting within the same system. The advantages are low initial capital requirement for high energy. Best results for iron based alloys. Spindle and Drag machines The energy of the spindle equipment is generated by a stationary or rotating bowl of wet or dry media with a number of stationary or moving and rotating spindles that holds the parts into the media. The drag machines use the spindles to move or drag the process parts thru a dense non moving media within a tub. The dense non moving media creates a very high metal removal rate. The slight vibration of media reduces the machine horsepower require and introduces new media to the cut area. MASS FINISHING TECHNICAL INFORMATION The spindle and drag machines can run larger parts that are held or fixtured for a high metal removal, super burr removal or high luster finishing. Chemical finishing has been introduced with these systems to improve them futher. Energy levels Very high Media action Spinning by the part with spindle machines and densely laying in the tub for drag machines. Both utilize spindles or work holding devices. Application Turbines and propellers for high metal removal, high capital outlay. Low Energy Systems Barrels The barrel equipments energy is produced by a rotating hexagon or octagon shaped barrel where its design lifts the media and parts loaded within. The flat sides of the barrel lifts the media and process parts up for the slide down.The finishing action is taking place only on the downward slide.
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